Patent Application
20240124660
Certain configurations described herein are directed to reinforced thermoplastic articles that are highly consolidated. More particularly, certain embodiments of articles that include a lighter weight core layer that has comparable mechanical properties to a heavier core layer.
Thermoplastic articles are often produced at heavy weights to achieve improved mechanical properties. Increasing the overall weight of the articles can require more materials and result in handling complications.
Certain aspects are directed to reinforced thermoplastic composite articles with reduced areal densities that retain the mechanical properties of articles having higher areal densities. Certain configurations may permit the article to have an increased overall thickness while retaining the mechanical properties of articles having a reduced thickness. Some arrangements use a highly consolidated porous core layer to provide enhanced overall thickness after lofting while retaining the mechanical properties of articles having a reduced thickness.
In an aspect, a reinforced thermoplastic composite article comprises a consolidated, porous core layer. In certain configurations, the consolidated, porous core layer comprises a consolidated, porous web. The consolidated, porous web comprises reinforcing materials held in place by a thermoplastic material to provide open cell structures within the consolidated, porous web. The consolidated, porous web can also include a lofting agent in the open cell structures. In certain embodiments, the consolidated, porous core layer comprises an average flexural slope, an average flexural stiffness and an average tensile modulus that is comparable to an average flexural slope, an average flexural stiffness and an average tensile modulus of a control specimen when the consolidated, porous core layer has a basis weight that is at least 25% less than a basis weight of the control specimen.
In certain examples, a ratio of the thermoplastic material to the reinforcing materials is 1.25:1 or greater. In other examples, the consolidated, porous web comprises a lofting capacity to increase a thickness of the consolidated, porous web to greater than 4 mm after fully lofting the consolidated, porous web to provide a fully lofted porous web. In some embodiments, the consolidated, porous core layer comprises an as-produced density of greater than 0.40 g/cm3 and an as-produced areal density of less than 2000 g/m2. In other embodiments, a thickness of the fully lofted porous web is greater than 8 mm or greater than 9 mm or greater than 10 mm.
In certain configurations, the reinforced thermoplastic composite article comprises a flexural peak load in a machine direction of at least 20 N when tested by ASTM D790-17. In other configurations, the reinforced thermoplastic composite article comprises a flexural peak load in a cross direction of at least 15 N when tested by ASTM D790-17. In some embodiments, the reinforced thermoplastic composite article comprises a flexural stiffness in a machine direction of at least 100 N/cm when tested by ASTM D790-17. In other embodiments, the reinforced thermoplastic composite article comprises a flexural stiffness in a cross direction of at least 60 N/cm when tested by ASTM D790-17. In additional embodiments, the reinforced thermoplastic composite article comprises a flexural peak load in a machine direction of at least 10 N and a flexural peak load in a cross direction of at least 7.5 N when tested by ASTM D790-17. In some configurations, the reinforced thermoplastic composite article comprises a flexural stiffness in a machine direction of at least 80 N/cm and a flexural stiffness in a cross direction of at least 50 N/cm when tested by ASTM D790-17.
In certain embodiments, the reinforced thermoplastic composite article comprises a first layer coupled to a first surface of the consolidated, porous web. In some examples, the first layer is an adhesive layer or a skin layer. In some embodiments, the skin layer comprises one or more of a film, a scrim, a foil, a woven fabric, a non-woven fabric or a coating,
In other embodiments, the thermoplastic material comprises a polyolefin, the reinforcing materials comprises glass fibers, the lofting agent comprises expandable microspheres, wherein the ratio of polyolefin to glass fibers is 1.45:1 or more, and the thickness of the fully lofted porous web is 8 mm or more. In some examples, the polyolefin is polypropylene. In other examples, the consolidated, porous core layer comprises an as-produced density of greater than 0.40 g/m3 and an as-produced areal density of less than 2000 g/m2.
In some embodiments, the reinforced thermoplastic composite article comprises a second layer coupled to a second surface of the of the consolidated, porous web. In certain examples, the thermoplastic material is a polypropylene, the reinforcing materials are reinforcing glass fibers and the lofting agent is expandable microspheres. In some embodiments, the reinforced thermoplastic composite article comprises a flexural peak load in a machine direction of at least 15 N and a flexural peak load in a cross direction of at least 10 N when tested by ASTM D790-17. In certain embodiments, the reinforced thermoplastic composite article comprises a flexural stiffness in a machine direction of at least 80 N/cm and a flexural stiffness in a cross direction of at least 50 N/cm when tested by ASTM D790-17.
In another aspect, a method of producing a thermoplastic composite article with a consolidated, porous core layer having a high strength to weight ratio is provided. In certain embodiments, the method comprises combining a thermoplastic material, reinforcing materials and a lofting agent in an aqueous slurry to provide a mixture of the thermoplastic material, the reinforcing materials and the lofting agent. The method can also include depositing the mixture on a moving support. The method can also include removing water from the deposited mixture on the moving support to provide a web. The method can also include heating the web to form a porous web comprising open cells formed from the reinforcing materials held in place by the thermoplastic material, wherein the lofting agent is trapped in the open cells of the formed, porous web. The method can also include pressing the formed, porous web using pressure applied to at least one surface of the formed, porous web. The method can also include consolidating the pressed web to provide a consolidated, porous core layer.
In certain embodiments, the pressing comprises passing the formed, porous web between a set of rollers having a defined gap width. In other embodiments, the consolidating comprises heating the pressed web for a dwell time. In some examples, the dwell time is 20 seconds to 60 seconds. In certain embodiments, the consolidating is performed on a support separate from the moving support. In other embodiments, the pressing and consolidating are performed on a support separate from the moving support. In some examples, a ratio of the thermoplastic material:reinforcing materials in the aqueous slurry is at least 1.5:1. In other examples, a basis weight of the consolidated, porous core layer is less than 2000 gsm. In some configurations, an as-produced density of the consolidated, porous core layer is greater than 0.40 g/cm3.
In certain embodiments, the thermoplastic material is polypropylene, the reinforcing materials are reinforcing glass fibers, the lofting agent is a microsphere lofting agent, and wherein the consolidated porous core layer has a fully lofted thickness of 8 mm or greater.
In another aspect, a system configured to produce a thermoplastic composite article with a consolidated, porous core layer having a high strength to weight ratio is described. In certain configurations, the system comprises a reservoir, a moving support, a heating device, a pressure device, a consolidating device and a processor. In certain embodiments, the reservoir is configured to receive a thermoplastic material and reinforcing materials and mix the received thermoplastic material and reinforcing materials to provide a mixture. In other embodiments, the moving support is fluidically coupled to the reservoir and configured to receive and retain the mixture from the reservoir. In some examples, the heating device configured to receive the moving support with the mixture from the reservoir and form a porous web. In other examples, the pressure device is configured to apply pressure to at least one surface of the formed porous web. In some embodiments, the consolidating device configured to heat the pressed porous web to provide a consolidated, porous web. The processor can be electrically coupled to the reservoir, the moving support, the heating device, the pressure device and the consolidating device and used to control the system.
In certain embodiments, the system can include a pressure device, e.g., a vacuum device configured to remove water from the mixture on the moving support. In other embodiments, the moving support comprises a wire screen with a constant mesh size or a variable mesh size. In some embodiments, the heating device is an oven. In some configurations, the pressure device comprises at least one pair of rollers with a defined gap between them, wherein the porous web passed through the defined gap to press the porous web to a lower thickness. In other configurations, the consolidating device comprises an oven. In additional embodiments, the processor is configured to control a deposition rate of the mixture from the reservoir onto the moving support, to control a speed of the moving support, to control a temperature of the heating device, to control a pressure to be applied by the pressure device and to control a temperature provided by the consolidation device to produce the consolidated, porous core layer. In other embodiments, the consolidating device comprises a support separate from the moving support. In some examples, the pressure device and the consolidating device comprise a support separate from the moving support. In some embodiments, the system can also include a mold.
In another aspect, an automotive article comprising the reinforced thermoplastic composite articles described herein is provided.
Additional aspects, configurations, embodiments and examples are described in more detail below.
Certain specific illustrations are described below to facilitate a better understanding of the technology described herein with reference to the accompanying drawings in which:
It will be recognized by the person of ordinary skill in the art, given the benefit of this description, that the different layers described herein are not necessarily shown to scale. No material is intended to be required in any one layer unless specifically indicated in the description in connection with that particular configuration. The thicknesses, arrangements and end-uses of the articles may vary.
In certain embodiments, reducing the overall weight of thermoplastic articles while maintaining mechanical properties has been a focus in the automotive and building industries to improve fuel efficiency, lower CO2 emissions, provide for easier handling, etc. For example, lightweight reinforced thermoplastic (LWRT) articles can be used in automotive applications, including headliners, underbody shields, trunk trim, and rear window trim. LWRT articles can also be used in heavy truck applications, commercial truck applications, construction applications, in the building industry and in other applications where lightweight articles with high mechanical properties, e.g., flexural peak load and stiffness, and lower overall weight are desirable.
In some embodiments, reducing greenhouse gas emissions during transportation has been a focus in the past few years. In 2021, the federal government proposed and revised the standards for passenger cars and light-duty vehicles for the model year 2023-2026. The new standards were supported by the leading U.S. automakers, including General Motors, Stellantis, and Ford Motor Company. According to the new standard, the CO2 emission was restricted to 160 g/mile by 2026. A lightweight design that is capable of reducing automotive weight can be used as an efficient approach to achieving the goal of low emissions. Furthermore, Europe and Asia have also imposed stricter CO2 limits or higher average fuel economy requirements over the past few years.
In certain configurations, the LWRT articles described herein can have a high strength-to-weight ratio (compared to conventional LWRT articles) and can be molded or otherwise processed into complicated geometries with varying thicknesses. During the manufacturing process, to achieve better mechanical properties, a high consolidation level can be implemented while maintaining the same level (or better level) of mechanical properties with a significant areal density reduction compared to a standard LWRT counterpart. For example, the LWRT article can be highly consolidated, e.g., have a higher as-produced density and lower areal density in an as-produced state. This higher level of consolidation also generally decreases the overall thickness of the as-produced LWRT article making it easier to handle and store. The as-produced LWRT article can then be lofted, e.g., either alone or when used in combination with one or more other layers or skins, to an overall thickness which is typically higher than a standard LWRT article that includes a non-consolidated core layer.
In certain embodiments, the reinforced thermoplastic composite articles described herein comprise a consolidated, porous core layer. The consolidated, porous core layer comprises a consolidated, porous web comprising reinforcing materials held in place by a thermoplastic material to provide open cell structures within the consolidated, porous web. The consolidated, porous web comprises an optional lofting agent in the open cell structures. The consolidated, porous core layer comprises an average flexural slope and an average flexural stiffness that is comparable to an average flexural slope and an average flexural stiffness of control specimen when the consolidated, porous core layer has a basis weight that is at least 20% or at least 25% less than a basis weight of the control specimen. The control specimen is generally similar to the tested article but does not include a consolidated core layer. For example, the average flexural slope and the average flexural stiffness (at a particular molding thickness) of the consolidated, porous core layer and the control specimen may be the same or may differ by less than 5% even though the consolidated, porous core layer has a basis weight that is 20% less, 25% less (or at least 25% less) than a basis weight of the control specimen. Flexural slope, flexural stiffness and tensile modulus can be measured by ASTM D790-17 to determine these values. Comparable mechanical property values are considered to be the same values or values that differ by less than +/−5%.
In certain embodiments, a simplified illustration is shown in
In certain configurations, the control specimens can have a basis weight from 900 gsm to 2500 gsm. For example, the control specimen basis weight may be 900 gsm, 925 gsm, 950 gsm, 975 gsm, 1000 gsm, 1025 gsm, 1050 gsm, 4100 gsm, 1125, gsm, 1150 gsm, 1175 gsm or 1200 gsm, 1300 gsm, 1400 gsm, 1500 gsm, 1600 gsm, 1700 gm, 1800 gsm, 1900 gsm, 2000 gsm, 2100 gsm, 2200 gsm, 2300 gsm, 2400 gsm or 2500 gsm. The consolidated porous core layer typically has a basis weight lower than 2000 gsm. For example, the basis weight of the consolidated porous core layer can be 500 gsm, 525 gsm, 850 gsm, 575 gsm, 600 gsm, 625 gsm, 650 gsm, 675 gsm, 700 gsm, 725 gsm, 750 gsm, 775 gsm, 800 gsm, 825 gsm, 850 gsm, 875 gsm. 900 gsm, 950 gsm, 1000 gsm, 1050 gsm, 1100 gsm, 1150 gsm, 1200 gsm, 1250 gsm, 1300 gsm, 1350 gsm, 1400 gsm, 1450 gsm, 1500 gsm, 1550 gsm, 1600 gsm, 1650 gsm, 1700 gsm, 1750 gsm, 1800 gsm, 1850 gsm, 1900 gsm, 1950 gsm or 2000 gsm or any value between about 300 gsm and less than or equal to 2000 gsm.
In certain embodiments, a consolidated, porous core layer with a 21% lower basis weight (compared to a basis weight of the control specimen) may have one or more of a comparable average flexural slope, average flexural stiffness and/or average tensile modulus as the control specimen. The consolidated, porous core layer and the control specimen may be molded to about the same thickness for comparison. The average flexural slope, the average flexural stiffness and/or average tensile modulus of the consolidated, porous core layer and the control specimen may differ by +/−5% or less and still be considered comparable. The thickness of the control specimen and consolidated specimen can be about the same, e.g., within +/−5%.
In some embodiments, a consolidated, porous core layer with a 22% lower basis weight (compared to a basis weight of the control specimen) may have one or more of a comparable average flexural slope, average flexural stiffness and/or average tensile modulus as the control specimen. The consolidated, porous core layer and the control specimen may be molded to about the same thickness for comparison. The average flexural slope, the average flexural stiffness and/or average tensile modulus of the consolidated, porous core layer and the control specimen may differ by +/−5% or less and still be considered comparable. The thickness of the control specimen and consolidated specimen can be about the same, e.g., within +/−5%.
In certain embodiments, a consolidated, porous core layer with a 23% lower basis weight (compared to a basis weight of the control specimen) may have one or more of a comparable average flexural slope, average flexural stiffness and/or average tensile modulus as the control specimen. The consolidated, porous core layer and the control specimen may be molded to about the same thickness for comparison. The average flexural slope, the average flexural stiffness and/or average tensile modulus of the consolidated, porous core layer and the control specimen may differ by +/−5% or less and still be considered comparable. The thickness of the control specimen and consolidated specimen can be about the same, e.g., within +/−5%.
In some embodiments, a consolidated, porous core layer with a 24% lower basis weight (compared to a basis weight of the control specimen) may have one or more of a comparable average flexural slope, average flexural stiffness and/or average tensile modulus as the control specimen. The consolidated, porous core layer and the control specimen may be molded to about the same thickness for comparison. The average flexural slope, the average flexural stiffness and/or average tensile modulus of the consolidated, porous core layer and the control specimen may differ by +/−5% or less and still be considered comparable. The thickness of the control specimen and consolidated specimen can be about the same, e.g., within +/−5%.
In some configurations, a consolidated, porous core layer with a 25% lower basis weight (compared to a basis weight of the control specimen) may have one or more of a comparable average flexural slope, average flexural stiffness and/or average tensile modulus as the control specimen. The consolidated, porous core layer and the control specimen may be molded to about the same thickness for comparison. The average flexural slope, the average flexural stiffness and/or average tensile modulus of the consolidated, porous core layer and the control specimen may differ by +/−5% or less and still be considered comparable. The thickness of the control specimen and consolidated specimen can be about the same, e.g., within +/−5%.
In some embodiments, a consolidated, porous core layer with a 26% lower basis weight (compared to a basis weight of the control specimen) may have one or more of a comparable average flexural slope, average flexural stiffness and/or average tensile modulus as the control specimen. The consolidated, porous core layer and the control specimen may be molded to about the same thickness for comparison. The average flexural slope, the average flexural stiffness and/or average tensile modulus of the consolidated, porous core layer and the control specimen may differ by +/−5% or less and still be considered comparable. The thickness of the control specimen and consolidated specimen can be about the same, e.g., within +/−5%.
In other embodiments, a consolidated, porous core layer with a 27% lower basis weight (compared to a basis weight of the control specimen) may have one or more of a comparable average flexural slope, average flexural stiffness and/or average tensile modulus as the control specimen. The consolidated, porous core layer and the control specimen may be molded to about the same thickness for comparison. The average flexural slope, the average flexural stiffness and/or average tensile modulus of the consolidated, porous core layer and the control specimen may differ by +/−5% or less and still be considered comparable. The thickness of the control specimen and consolidated specimen can be about the same, e.g., within +/−5%.
In some embodiments, a consolidated, porous core layer with a 28% lower basis weight (compared to a basis weight of the control specimen) may have one or more of a comparable average flexural slope, average flexural stiffness and/or average tensile modulus as the control specimen. The consolidated, porous core layer and the control specimen may be molded to about the same thickness for comparison. The average flexural slope, the average flexural stiffness and/or average tensile modulus of the consolidated, porous core layer and the control specimen may differ by +/−5% or less and still be considered comparable. The thickness of the control specimen and consolidated specimen can be about the same, e.g., within +/−5%.
In other embodiments, a consolidated, porous core layer with a 29% lower basis weight (compared to a basis weight of the control specimen) may have one or more of a comparable average flexural slope, average flexural stiffness and/or average tensile modulus as the control specimen. The consolidated, porous core layer and the control specimen may be molded to about the same thickness for comparison. The average flexural slope, the average flexural stiffness and/or average tensile modulus of the consolidated, porous core layer and the control specimen may differ by +/−5% or less and still be considered comparable. The thickness of the control specimen and consolidated specimen can be about the same, e.g., within +/−5%.
In some embodiments, a consolidated, porous core layer with a 30% lower basis weight (compared to a basis weight of the control specimen) may have one or more of a comparable average flexural slope, average flexural stiffness and/or average tensile modulus as the control specimen. The consolidated, porous core layer and the control specimen may be molded to about the same thickness for comparison. The average flexural slope, the average flexural stiffness and/or average tensile modulus of the consolidated, porous core layer and the control specimen may differ by +/−5% or less and still be considered comparable. The thickness of the control specimen and consolidated specimen can be about the same, e.g., within +/−5%.
In other embodiments, a consolidated, porous core layer with a 31% lower basis weight (compared to a basis weight of the control specimen) may have one or more of a comparable average flexural slope, average flexural stiffness and/or average tensile modulus as the control specimen. The consolidated, porous core layer and the control specimen may be molded to about the same thickness for comparison. The average flexural slope, the average flexural stiffness and/or average tensile modulus of the consolidated, porous core layer and the control specimen may differ by +/−5% or less and still be considered comparable. The thickness of the control specimen and consolidated specimen can be about the same, e.g., within +/−5%.
In some embodiments, a consolidated, porous core layer with a 32% lower basis weight (compared to a basis weight of the control specimen) may have one or more of a comparable average flexural slope, average flexural stiffness and/or average tensile modulus as the control specimen. The consolidated, porous core layer and the control specimen may be molded to about the same thickness for comparison. The average flexural slope, the average flexural stiffness and/or average tensile modulus of the consolidated, porous core layer and the control specimen may differ by +/−5% or less and still be considered comparable. The thickness of the control specimen and consolidated specimen can be about the same, e.g., within +/−5%.
In other embodiments, a consolidated, porous core layer with a 33% lower basis weight (compared to a basis weight of the control specimen) may have one or more of a comparable average flexural slope, average flexural stiffness and/or average tensile modulus as the control specimen. The consolidated, porous core layer and the control specimen may be molded to about the same thickness for comparison. The average flexural slope, the average flexural stiffness and/or average tensile modulus of the consolidated, porous core layer and the control specimen may differ by +/−5% or less and still be considered comparable. The thickness of the control specimen and consolidated specimen can be about the same, e.g., within +/−5%.
In some embodiments, a consolidated, porous core layer with a 34% lower basis weight (compared to a basis weight of the control specimen) may have one or more of a comparable average flexural slope, average flexural stiffness and/or average tensile modulus as the control specimen. The consolidated, porous core layer and the control specimen may be molded to about the same thickness for comparison. The average flexural slope, the average flexural stiffness and/or average tensile modulus of the consolidated, porous core layer and the control specimen may differ by +/−5% or less and still be considered comparable. The thickness of the control specimen and consolidated specimen can be about the same, e.g., within +/−5%.
In other embodiments, a consolidated, porous core layer with a 35% lower basis weight (compared to a basis weight of the control specimen) may have one or more of a comparable average flexural slope, average flexural stiffness and/or average tensile modulus as the control specimen. The consolidated, porous core layer and the control specimen may be molded to about the same thickness for comparison. The average flexural slope, the average flexural stiffness and/or average tensile modulus of the consolidated, porous core layer and the control specimen may differ by +/−5% or less and still be considered comparable. The thickness of the control specimen and consolidated specimen can be about the same, e.g., within +/−5%.
In other embodiments, a consolidated, porous core layer with at least a 35% lower basis weight (compared to a basis weight of the control specimen) may have one or more of a comparable average flexural slope, average flexural stiffness and/or average tensile modulus as the control specimen. For example, the basis weight may be 35-50% lower, may be 35-45% lower or may be 35-40% lower than a control specimen. The consolidated, porous core layer and the control specimen may be molded to about the same thickness for comparison. The average flexural slope, the average flexural stiffness and/or average tensile modulus of the consolidated, porous core layer and the control specimen may differ by +/−5% or less and still be considered comparable. The thickness of the control specimen and consolidated specimen can be about the same, e.g., within +/−5%.
In certain embodiments, the exact mechanical property values can vary with basis weight of the consolidated, porous core layer. In some embodiments, an article including a consolidated, porous core layer comprises a flexural peak load in the machine direction of at least 20 N, e.g., at least 25 N, 30 N, 35 N, 40 N, 45 N, 50 N or more. In other embodiments, an article including a consolidated, porous core layer comprises a flexural peak load in the cross direction of at least 15 N, e.g., at least 20 N, 25 N, 30 N, 35 N, 40N or more. In other embodiments, an article including a consolidated, porous core layer comprises a flexural stiffness in a machine direction of at least 100 N/cm when tested by ASTM D790-17, e.g., at least 110 N/cm, 115 N/cm, 120 N/cm, 125 N/cm or at least 130 N/cm. In certain embodiments, an article including a consolidated, porous core layer comprises a flexural stiffness in a cross direction of at least 60 N/cm when tested by ASTM D790-17, e.g., at least 65 N/cm, 70, N/cm, 75 N/cm, 80 N/cm or at least 85 N/cm. In certain examples, an article including a consolidated, porous core layer comprises a tensile modulus in a machine direction of at least 1000 MPa when tested by ASTM D790-17, e.g., at least 1050 MPa, 1100 MPa, 1150 MPa, 1200 MPa, 1250 MPa, 1300 MPa or at least 1350 MPa. In certain embodiments, an article including a consolidated, porous core layer comprises a tensile modulus in a cross direction of at least 500 MPa when tested by ASTM D790-17, e.g., at least 550 MPa, 600 MPa, 650 MPa, 700 MPa or at least 750 MPa. In certain examples, an article including a consolidated, porous core layer comprises a tensile slope in a machine direction of at least 700 N/cm when tested by ASTM D790-17, e.g., at least 725 N/cm, 750 N/cm, 775 N/cm, 800 N/cm or at least 825 N/cm. In certain embodiments, an article including a consolidated, porous core layer comprises a tensile slope in a cross direction of at least 250 N/cm when tested by ASTM D790-17, e.g., at least 275 N/cm, 300 N/cm, 325 N/cm, 350 N/cm or at least 375 N/cm.
In some embodiments, an article including a consolidated, porous core layer comprises a flexural peak load in the machine direction of at least 10 N as measured by ASTM D790-17, e.g., at least 11 N, 12 N, 13 N, 14 N, 15 N, 16 N, 17 N, 18 N, 19 N or more. In other embodiments, an article including a consolidated, porous core layer comprises a flexural peak load in the cross direction of at least 7.5 N as measured by ASTM D790-17, e.g., at least 8 N, 8.5 N, 9 N, 9.5 N, 10 N, 10.5 N, 11 N, 11.5 N, 12 N or more. In other embodiments, an article including a consolidated, porous core layer comprises a flexural stiffness in a machine direction of at least 80 N/cm when tested by ASTM D790-17, e.g., at least 82.5 N/cm, 85 N/cm, 87.5 N/cm, 90 N/cm or at least 92.5 N/cm. In certain embodiments, an article including a consolidated, porous core layer comprises a flexural stiffness in a cross direction of at least 50 N/cm when tested by ASTM D790-17, e.g., at least 51 N/cm, 52 N/cm, 53 N/cm, 54 N/cm or at least 55 N/cm. In certain examples, an article including a consolidated, porous core layer comprises a tensile modulus in a machine direction of at least 750 MPa when tested by ASTM D790-17, e.g., at least 775 MPa, 800 MPa, 825 MPa, 850 MPa, 875 MPa, 900 MPa or at least 925 MPa. In certain embodiments, an article including a consolidated, porous core layer comprises a tensile modulus in a cross direction of at least 350 MPa when tested by ASTM D790-17, e.g., at least 375 MPa, 400 MPa, 425 MPa, 450 MPa or at least 475 MPa. In certain examples, an article including a consolidated, porous core layer comprises a tensile slope in a machine direction of at least 500 N/cm when tested by ASTM D790-17, e.g., at least 525 N/cm, 550 N/cm, 575 N/cm, 600 N/cm or at least 625 N/cm. In certain embodiments, an article including a consolidated, porous core layer comprises a tensile slope in a cross direction of at least 175 N/cm when tested by ASTM D790-17, e.g., at least 200 N/cm, 210 N/cm, 220 N/cm, 230 N/cm or at least 240 N/cm. These illustrative values can be obtained by measuring the particular mechanical property after the consolidated, porous core layer has been molded to a desired thickness. In general, lower basis weight consolidated core layers will tend to have average lower mechanical values, though this trend can vary depending on which particular materials are present.
In certain embodiments, the LWRT articles described herein typically include a porous core layer optionally in combination with one or more other layers, e.g., skins, other core layers, etc. The terms “prepreg” and “core” may be used herein. A core is typically a formed and cooled prepreg. The prepreg may be produced by heating the specific materials as noted in more detail below. In certain configurations, the porous core layer comprises a web formed from reinforcing materials held in place by a thermoplastic material. A simplified illustration is shown in
In certain embodiments, the thermoplastic material present in the core layer 410 may comprise different forms including, but not limited to, fiber form, particle form, resin form or other suitable forms. In some examples, the thermoplastic material may comprise a polyolefin or other thermoplastic materials. For example, the thermoplastic material may comprise one or more of polyethylene, polypropylene, polystyrene, acrylonitrylstyrene, butadiene, polyethyleneterephthalate, polybutyleneterephthalate, polybutylenetetrachlorate, and polyvinyl chloride, both plasticized and unplasticized, and blends of these materials with each other or other polymeric materials. Other suitable thermoplastics include, but are not limited to, polyarylene ethers, polycarbonates, polyestercarbonates, thermoplastic polyesters, polyimides, polyetherimides, polyamides, acrylonitrile-butylacrylate-styrene polymers, amorphous nylon, polyarylene ether ketone, polyphenylene sulfide, polyaryl sulfone, polyether sulfone, liquid crystalline polymers, poly(1,4 phenylene) compounds commercially known as PARMAX®, high heat polycarbonate such as Bayer's APEC® PC, high temperature nylon, and silicones, as well as alloys and blends of these materials with each other or other polymeric materials In some instances, the resin may be a polyetherimide resin such as an Ultem® resin. The Ultem® resin can be filled or unfilled may be selected so it is UL94 V-0 rated with low smoke KPSI FDA, USDA, USP Class VI & NSF Approved. If desired, the Ultem® resin may be glass-reinforced, e.g., 30% glass-filled (Ultem 2300), 20% glass-filled (Ultem 5200), or 10% glass-filled (Ultem 2100). If desired, a thermoplastic blend, which can be a blend including a thermoplastic material or a thermosetting material, may be present in the core layer 410. The exact amount of thermoplastic material in the core layer 410 may vary and includes, but is not limited to, about 10% by weight to about 90% by weight of the core layer 410, e.g., about 20% by weight to about 80% by weight or about 30% by weight to about 70% by weight or about 40% by weight to about 60% by weight based on the total weight of the core layer 410.
In some examples, the exact amount of reinforcing materials, e.g., reinforcing fibers, filaments, flakes, powders, pellets, whiskers, etc., present in the core layer 410 may vary. For example, the reinforcing material or fiber content in the core layer 410 may be greater than 0% by weight to about 90% by weight, e.g., about 1% to about 80% by weight of the core layer 410, more particularly from about 2% to about 80%, by weight of the core layer 410 or about 20% by weight to about 80% by weight of the core layer 410 or about 30% by weight to about 70% by weight of the core layer 410. The particular size and/or orientation of the fibers used may depend, at least in part, on the polymer material used and/or the desired properties of the resulting prepreg or core. Suitable additional types of reinforcing materials include but are not limited to particles, powder, fibers and the like. Where reinforcing fibers are present in the core layer 410, the reinforcing fibers may comprise one or more of glass fibers, polymeric fibers, polymeric bicomponent fibers, carbon fibers, graphite fibers, synthetic organic fibers, particularly high modulus organic fibers such as, for example, para- and meta-aramid fibers, nylon fibers, polyester fibers, or any of the high melt flow index resins described herein that are suitable for use as fibers, natural fibers such as hemp, sisal, jute, flax, coir, and kenaf, mineral fibers such as basalt, mineral wool (e.g., rock or slag wool), wollastonite, alumina, silica, and the like, or mixtures thereof, metal fibers, metalized natural and/or synthetic fibers, ceramic fibers, yarn fibers, or mixtures thereof, natural fibers, polymeric fibers or other types of fibers. In one non-limiting illustration, reinforcing fibers dispersed within a thermoplastic material to provide a prepreg or core generally have a diameter of greater than about 5 microns, more particularly from about 5 microns to about 22 microns, and a length of from about 5 mm to about 200 mm, more particularly, the fiber diameter may be from about 3 nanometers to about 22 microns and the fiber length may be from about 5 mm to about 75 mm.
In some examples, to achieve improved strength to weight properties, at least in part, the composite articles described herein can generally include more thermoplastic material by weight of the web than reinforcing materials by weight of the web. For example, the amount of thermoplastic material in the web may be 50% by weight or more, and the amount of reinforcing materials in the web may be less than 50% by weight. In some embodiments, the amount of thermoplastic material in the web may be between 51 weight percent and 80 weight percent, and the amount of reinforcing material in the web may be between 20 weight percent and 49 weight percent. In other embodiments, the amount of thermoplastic material in the web may be between 52 weight percent and 80 weight percent, and the amount of reinforcing material in the web may be between 20 weight percent and 48 weight percent. In other embodiments, the amount of thermoplastic material in the web may be between 53 weight percent and 80 weight percent, and the amount of reinforcing material in the web may be between 20 weight percent and 47 weight percent. In certain embodiments, the amount of thermoplastic material in the web may be between 54 weight percent and 80 weight percent, and the amount of reinforcing material in the web may be between 20 weight percent and 46 weight percent. In some embodiments, the amount of thermoplastic material in the web may be between 55 weight percent and 80 weight percent, and the amount of reinforcing material in the web may be between 20 weight percent and 45 weight percent. In other embodiments, the amount of thermoplastic material in the web may be between 56 weight percent and 80 weight percent, and the amount of reinforcing material in the web may be between 20 weight percent and 44 weight percent. In certain embodiments, the amount of thermoplastic material in the web may be between 57 weight percent and 80 weight percent, and the amount of reinforcing material in the web may be between 20 weight percent and 43 weight percent. In some embodiments, the amount of thermoplastic material in the web may be between 58 weight percent and 80 weight percent, and the amount of reinforcing material in the web may be between 20 weight percent and 42 weight percent. In other embodiments, the amount of thermoplastic material in the web may be between 59 weight percent and 80 weight percent, and the amount of reinforcing material in the web may be between 20 weight percent and 41 weight percent. In certain embodiments, the amount of thermoplastic material in the web may be between 60 weight percent and 80 weight percent, and the amount of reinforcing material in the web may be between 20 weight percent and 40 weight percent. Where a lofting agent is present, an amount of the thermoplastic material or reinforcing fibers, or both, can be reduced.
In some embodiments, the weight percentage ratio of the thermoplastic material:reinforcing materials (e.g., weight percentage of thermoplastic material:weight percentage of reinforcing materials) may be 1.05:1 or greater, e.g., 1.10:1, 1.15:1, 1.20:1, 1.25:1, 1.30:1, 1.35:1, 1.40:1, 1.45:1, 1.50:1, 1.55:1, 1.65:1, 1.70:1, 1.75:1 or greater than 1.75:1. Where the thermoplastic material is a polyolefin, e.g., polyethylene, polypropylene, etc., the weight percentage ratio of the polyolefin:reinforcing materials may be 1.05:1 or greater, e.g., 1.10:1, 1.15:1, 1.20:1, 1.25:1, 1.30:1, 1.35:1, 1.40:1, 1.45:1, 1.50:1, 1.55:1, 1.65:1, 1.70:1, 1.75:1 or greater than 1.75:1. Where the reinforcing materials are reinforcing fibers, the weight percentage ratio of the thermoplastic material:reinforcing fibers may be 1.05:1 or greater, e.g., 1.10:1, 1.15:1, 1.20:1, 1.25:1, 1.30:1, 1.35:1, 1.40:1, 1.45:1, 1.50:1, 1.55:1, 1.65:1, 1.70:1, 1.75:1 or greater than 1.75:1. Where the thermoplastic material is a polyolefin and the reinforcing materials are reinforcing fibers, the weight percentage ratio of the polyolefin:reinforcing fibers may be 1.05:1 or greater, e.g., 1.10:1, 1.15:1, 1.20:1, 1.25:1, 1.30:1, 1.35:1, 1.40:1, 1.45:1, 1.50:1, 1.55:1, 1.65:1, 1.70:1, 1.75:1 or greater than 1.75:1. Where the thermoplastic material is a polypropylene and the reinforcing materials are reinforcing fibers, the weight percentage ratio of the polypropylene:reinforcing fibers may be 1.05:1 or greater, e.g., 1.10:1, 1.15:1, 1.20:1, 1.25:1, 1.30:1, 1.35:1, 1.40:1, 1.45:1, 1.50:1, 1.55:1, 1.65:1, 1.70:1, 1.75:1 or greater than 1.75:1. Where the thermoplastic material is a polypropylene and the reinforcing materials are reinforcing glass fibers, the weight percentage ratio of the polypropylene:reinforcing glass fibers may be 1.05:1 or greater, e.g., 1.10:1, 1.15:1, 1.20:1, 1.25:1, 1.30:1, 1.35:1, 1.40:1, 1.45:1, 1.50:1, 1.55:1, 1.65:1, 1.70:1, 1.75:1 or greater than 1.75:1.
In certain embodiments, a basis weight of the as-produced porous web may be less than 2000, 1000 or 900 g/m2 (gsm) even though the porous web may have mechanical properties, e.g., flexural peak load, stiffness, flexural slope, similar to or better than a corresponding web with a basis weight of 2000 gsm or more. For example, an as-produced areal density of the composite article can be 300 gsm and up to 2000 gsm while retaining the mechanical properties of a corresponding web with a basis weight of more than 2000 gsm. In other embodiments, a basis weight of the as-produced porous web may be less than 1000 g/m2 (gsm) even though the porous web may have mechanical properties, similar to or better than a corresponding web with a basis weight of 1000 gsm or more. For example, an as-produced area density of the composite article can be 300 gsm and up to 900 gsm while retaining the mechanical properties of a corresponding web with a basis weight of 1000 gsm or more.
In certain configurations, the exact mechanical properties of the web may vary with web density and lofted thickness. Notwithstanding that the mechanical properties of the high strength to weight ratio webs described herein generally increase at higher as-produced areal densities, the exact areal density used may vary depending on the desired lofted thickness and/or desired mechanical properties. An increase in areal density of the as-produced web typically leads to an increase in a thickness of the fully lofted porous web.
In certain embodiments, the as-produced density of the consolidated porous web can be at least 0.40 g/cm3 and up to 0.8 g/cm3. The areal density of the as-produced consolidated porous core layer can be 300 gsm up to 2000 gsm. The post-lofted thickness of the fully lofted web can be greater than 7 mm, greater than 8 mm, greater than 9 mm or greater than 10 mm. Overall molding thickness of the consolidated, porous core layer is typically higher than a comparable non-consolidated core layer. For example, the high strength to weight ratio webs described herein typically have a higher lofting capacity than conventional webs, so the overall final thickness of the web is higher. The web can be lofted, for example, by heating the consolidated, porous web to a suitable temperature for a suitable period. The exact temperature and time can vary and illustrative temperatures include, for example, 170 deg. Celsius to 200 deg Celsius. In practice, the consolidated, porous web is often held at the lofting temperature for a suitable period so the consolidated, porous web fully lofts, e.g., expands to a maximum possible thickness. The exact lofted thickness, however, may be reduced if the web is molded and the spacing between the mold surfaces is less than a potential thickness of a fully lofted porous web.
In certain embodiments, when an as-produced web/core with an as-produced areal density of 650 gsm to 750 gsm and an overall thickness between 2.5 mm and 4 mm is used, the web may have one or more of the following mechanical properties: a peak load in the machine direction of at least 15 N, a peak load in the cross direction of at least 9 N, flexural stiffness in the machine direction of at least 80 N/cm, and a flexural stiffness in the cross direction of at least 45 N/cm. Unless otherwise stated, the mechanical properties listed herein are tested according to ASTM D790-17.
In other embodiments, when an as-produced web/core with an areal density of 750 gsm to 850 gsm and an overall thickness between 2.5 mm and 4 mm is used, the web may have one or more of the following mechanical properties: a peak load in the machine direction of at least 18 N, a peak load in the cross direction of at least 11 N, flexural stiffness in the machine direction of at least 100 N/cm, and a flexural stiffness in the cross direction of at least 50 N/cm.
The mechanical properties of the high strength to weight ratio porous webs/cores may be linear with increasing thickness but need not be linear with increasing thickness. For example, the peak load properties of a porous web may increase linearly as post-lofted thickness increases, may decrease linearly as post-lofted thickness increases or may have a constant slope as post-lofted thickness increases. The trend in mechanical properties may vary depending on the particular thermoplastic material and reinforcing materials used and their amounts and the overall final thickness of the lofted core layer.
In some embodiments, core layer 410 can be used, e.g., is compatible, with a first layer, which can be a skin layer, an adhesive layer or other layers. Referring to
In certain examples, the skin layer 630 may comprise a film (e.g., thermoplastic film or elastomeric film), a frim, a scrim (e.g., fiber based scrim or a scrim comprising natural fibers), a foil, a woven fabric, a non-woven fabric or be present as an inorganic coating, an organic coating, or a thermoset coating disposed on the prepreg or core 410. In other instances, the skin layer 630 may comprise a limiting oxygen index greater than about 22, as measured per ISO 4589 dated 1996. Where a thermoplastic film is present as (or as part of) the skin layer 630, the thermoplastic film may comprise at least one of poly(ether imide), poly(ether ketone), poly(ether-ether ketone), poly(phenylene sulfide), poly(arylene sulfone), poly(ether sulfone), poly(amide-imide), poly(1,4-phenylene), polycarbonate, nylon, and silicone. Where a fiber based scrim is present as (or as part of) the skin layer 630, the fiber based scrim may comprise at least one of glass fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers, metal fibers, metalized synthetic fibers, and metalized inorganic fibers. Where a thermoset coating is present as (or as part of) the skin layer 630, the coating may comprise at least one of unsaturated polyurethanes, vinyl esters, phenolics and epoxies. Where an inorganic coating is present as (or as part of) the skin layer 630, the inorganic coating may comprise minerals containing cations selected from Ca, Mg, Ba, Si, Zn, Ti and Al or may comprise at least one of gypsum, calcium carbonate and mortar. Where a non-woven fabric is present as (or as part of) the skin layer 630, the non-woven fabric may comprise a thermoplastic material, a thermal setting binder, inorganic fibers, metal fibers, metallized inorganic fibers and metallized synthetic fibers. If desired, the skin layer 630 may comprise an expandable graphite material, a flame retardant material, or other fibers and materials. The skin layer 630 can be formed on the layer 520 (or formed on the core 410) or may be added to the surface in a pre-formed state.
In certain configurations, a second layer 740, e.g., a second skin layer, can be present on an opposite surface of the core 410 as shown in
In other configurations, a decorative layer 850 can be present on one or both layers 630, 740. Alternatively, the decorative layer 850 could be coupled to a surface of the core layer 410 that does not include any skin layer or other layers. Referring to
In certain embodiments, two or more core layers can be stacked on top of each other to increase the overall thickness of the core. For example,
In certain embodiments, two core layers can be coupled to each other through an intermediate layer 1070 as shown in
In certain embodiments, the various core layers described herein may comprise other materials including additives, perfumes, scents, dyes, colorants, antioxidants or other materials as desired. In some configurations, the prepreg or core may be a substantially halogen free or halogen free prepreg or core to meet the restrictions on hazardous substances requirements for certain applications. In other instances, the prepreg or core may comprise a halogenated flame retardant agent (which can be present in the flame retardant material or may be added in addition to the flame retardant material) such as, for example, a halogenated flame retardant that comprises one of more of F, Cl, Br, I, and At or compounds that including such halogens, e.g., tetrabromo bisphenol-A polycarbonate or monohalo-, dihalo-, trihalo- or tetrahalo-polycarbonates. In some instances, the thermoplastic material used in the prepregs and cores may comprise one or more halogens to impart some flame retardancy without the addition of another flame retardant agent. Where halogenated flame retardants are present, the flame retardant is desirably present in a flame retardant amount, which can vary depending on the other components which are present. For example, the halogenated flame retardant where present may be present in about 0.1 weight percent to about 15 weight percent (based on the weight of the prepreg or core), more particularly about 1 weight percent to about 13 weight percent, e.g., about 5 weight percent to about 13 weight percent. If desired, two different halogenated flame retardants may be added to the prepregs or core. In other instances, a non-halogenated flame retardant agent such as, for example, a flame retardant agent comprising one or more of N, P, As, Sb, Bi, S, Se, and Te can be added. In some embodiments, the non-halogenated flame retardant may comprise a phosphorated material so the prepregs may be more environmentally friendly. Where non-halogenated or substantially halogen free flame retardants are present, the flame retardant is desirably present in a flame retardant amount, which can vary depending on the other components which are present. For example, the substantially halogen free flame retardant may be present in about 0.1 weight percent to about 15 weight percent (based on the weight of the prepreg or core), more particularly about 1 weight percent to about 13 weight percent, e.g., about 5 weight percent to about 13 weight percent based on the weight of the prepreg or core. If desired, two different substantially halogen free flame retardants may be added to the prepregs or cores. In certain instances, the prepregs or cores described herein may comprise one or more halogenated flame retardants in combination with one or more substantially halogen free flame retardants. Where two different flame retardants are present, the combination of the two flame retardants may be present in a flame retardant amount, which can vary depending on the other components which are present. For example, the total weight of flame retardants (exclusive of any compounded flame retardant material) present may be about 0.1 weight percent to about 20 weight percent (based on the weight of the prepreg or core), more particularly about 1 weight percent to about 15 weight percent, e.g., about 2 weight percent to about 14 weight percent based on the weight of the prepreg or core. The flame retardant agents used in the prepregs or cores described herein can be added to the mixture comprising the thermoplastic material and fibers (prior to disposal of the mixture on a wire screen or other processing component) or can be added after the prepreg or core is formed.
In other instances, the prepreg or core may comprise one or more acid scavengers. Illustrative acid scavengers include, but are not limited to, metal stearates and metal oxides, e.g., calcium stearate, zinc stearate, zinc oxide, calcium lactate or dihydrotalcite. These or other suitable acid scavengers can be used to deter discoloration of the prepregs and cores described herein. Alternatively, when discoloration is desired, the prepregs or core can be free of any acid scavengers, e.g., free or substantially free of a metal stearate or a metal oxide such as, for example, calcium stearate, zinc stearate, zinc oxide, or calcium lactate.
In some instances, a phenolic antioxidant may be present and used to manipulate the color of the composite article. For example, a thermoplastic composite article may comprise a porous core comprising reinforcing fibers and a thermoplastic material, wherein the porous core further comprises a metal hydroxide flame retardant and an antioxidant, wherein the porous core comprises a web formed from the reinforcing fibers held in place by the thermoplastic material, and wherein the antioxidant in the porous core comprising the metal hydroxide flame retardant, when exposed to oxidizing agent, changes color from a first color to a second color and when the oxidizing agent is removed changes color from the second color to the first color. Since the reaction where the phenolic antioxidant changes color can be reversed, the color can be favored or deterred depending on the particular environmental conditions present.
In some configurations, the prepreg or core layer may comprise other materials such as lofting agents, expandable microspheres, expandable graphite materials, hydroxides such as aluminum hydroxide or magnesium hydroxide or other materials. For example, lofting agents can reside in the core layer and may be present in a non-covalently bonded manner or a covalently bonded manner. Application of heat or other perturbations can act to increase the volume of the lofting agent which in turn increases the overall thickness of the layer, e.g., the layer increases as the size of the lofting agent increases and/or additional air becomes trapped in the layer. In addition, some lofting can be achieved by heating the prepreg or core layer even where no added lofting agent is present, e.g., there may be some intrinsic lofting capacity even in the absence of any added lofting agent. As noted herein, various devices can be used to consolidate the prepreg into a core with reduced thickness. Post-processing of the core can result in lofting or an increase in thickness of the prepreg or core layer. The exact amount of lofting agent present may vary, for example, from 0.5-15 weight percent based on the weight of the web.
In certain examples, the webs and articles described herein can be produced in many different manners including using wet laid processes or other process conditions. A simplified illustration is shown in
Another configuration of a system that can be used to produce the consolidated, porous webs is shown in
Another configuration of a system is shown in
In certain embodiments, a system under processor control can be used to produce the articles described herein. For example and referring to
In certain embodiments, the storage system used in the system 1400 described herein typically includes a computer readable and writeable nonvolatile recording medium in which codes of software can be stored that can be used by a program to be executed by the processor or information stored on or in the medium to be processed by the program. The medium may, for example, be a hard disk, solid state drive or flash memory. The program or instructions to be executed by the processor may be located locally or remotely and can be retrieved by the processor by way of an interconnection mechanism, a communication network or other means as desired. Typically, in operation, the processor causes data to be read from the nonvolatile recording medium into another memory that allows for faster access to the information by the processor than does the medium. This memory is typically a volatile, random access memory such as a dynamic random access memory (DRAM) or static memory (SRAM). It may be located in the storage system or in the memory system. The processor generally manipulates the data within the integrated circuit memory and then copies the data to the medium after processing is completed. A variety of mechanisms are known for managing data movement between the medium and the integrated circuit memory element and the technology is not limited thereto. The technology is also not limited to a particular memory system or storage system. In certain embodiments, the system may also include specially-programmed, special-purpose hardware, for example, an application-specific integrated circuit (ASIC), microprocessor units MPU) or a field programmable gate array (FPGA) or combinations thereof. Aspects of the technology may be implemented in software, hardware or firmware, or any combination thereof. Further, such methods, acts, systems, system elements and components thereof may be implemented as part of the systems described above or as an independent component. Although specific systems are described by way of example as one type of system upon which various aspects of the technology may be practiced, it should be appreciated that aspects are not limited to being implemented on the described system. Various aspects may be practiced on one or more systems having a different architecture or components. The system may comprise a general-purpose computer system that is programmable using a high-level computer programming language. The system may also implement specially programmed, special purpose hardware. In the systems, the processor is typically a commercially available processor such as the well-known microprocessors available from Intel, AMD, Apple and others. Many other processors are also commercially available. Such a processor usually executes an operating system which may be, for example, the Windows 7, Windows 8, Windows 10, or Windows 11 operating systems available from the Microsoft Corporation, MAC OS X, e.g., Snow Leopard, Lion, Mountain Lion, Mojave, High Sierra, El Capitan or other versions available from Apple, the Solaris operating system available from Sun Microsystems, or UNIX or Linux operating systems available from various sources. Many other operating systems may be used, and in certain embodiments a simple set of commands or instructions may function as the operating system.
In certain examples, the processor and operating system may together define a platform for which application programs in high-level programming languages may be written. It should be understood that the technology is not limited to a particular system platform, processor, operating system, or network. Also, it should be apparent to those skilled in the art, given the benefit of this disclosure, that the present technology is not limited to a specific programming language or computer system. Further, it should be appreciated that other appropriate programming languages and other appropriate systems could also be used. In certain examples, the hardware or software can be configured to implement artificial intelligence algorithms, cognitive architecture, neural networks or other suitable implementations. If desired, one or more portions of the computer system may be distributed across one or more computer systems coupled to a communications network. These computer systems also may be general-purpose computer systems. For example, various aspects may be distributed among one or more computer systems configured to provide a service (e.g., servers) to one or more client computers, or to perform an overall task as part of a distributed system. For example, various aspects may be performed on a client-server or multi-tier system that includes components distributed among one or more server systems that perform various functions according to various embodiments. These components may be executable, intermediate (e.g., IL) or interpreted (e.g., Java) code which communicate over a communication network (e.g., the Internet) using a communication protocol (e.g., TCP/IP). It should also be appreciated that the technology is not limited to executing on any particular system or group of systems. Also, it should be appreciated that the technology is not limited to any particular distributed architecture, network, or communication protocol.
In some configurations, various embodiments may be programmed using an object-oriented programming language, such as, for example, SQL, SmallTalk, Basic, Java, Javascript, PHP, C++, Ada, Python, iOS/Swift, Ruby on Rails or C# (C-Sharp). Other object-oriented programming languages may also be used. Alternatively, functional, scripting, and/or logical programming languages may be used. Various configurations may be implemented in a non-programmed environment (e.g., documents created in HTML, XML or other format that, when viewed in a window of a browser program, render aspects of a graphical-user interface (GUI) or perform other functions). Certain configurations may be implemented as programmed or non-programmed elements, or any combination thereof. In some instances, the systems may comprise a remote interface such as those present on a mobile device, tablet, laptop computer or other portable devices which can communicate through a wired or wireless interface and permit operation of the systems remotely as desired.
In certain examples, the processor may also comprise or have access to a database of information about parameters that can be used to provide porous core layers with a desired basis weight and/or consolidation level. The instructions stored in the memory can execute a software module or control routine for the system, which in effect can provide a controllable model of the system to permit production of a composite article with desired physical and mechanical properties. The processor can use information accessed from the database together with one or software modules executed in the processor to determine control parameters or values for different components of the systems, e.g., different temperatures and pressures, consolidation device dwell times, etc. Using input interfaces to receive control instructions and output interfaces linked to different system components in the system, the processor can perform active control over the system 1400. Where an optional mold 1480 is present, the mold 1480 is typically downstream of a consolidation device 1460. The mold 1480 can be used to heat the consolidated web, e.g., to loft the web. If desired, the mold 1480 could be replaced with an oven or other heating devices or thermoforming devices. In some embodiments, a skin layer, adhesive layer, etc. may be added to the web prior to providing the web to the mold 1480. For example, a skin layer may be continuously added to the web prior to providing the web to the pressure device 1450 or the heating device 1440. The pressure device 1450 can be used to laminate the skin to the web. The resulting article can be consolidated and then used later, optionally with additional layers and materials, to form a three-dimensional composite article using the mold 1480 or suitable thermoforming techniques.
In certain configurations, the articles and webs described herein can be used to provide a vehicle headliner. Illustrative vehicles include, but are not limited to, automotive vehicles, trucks, trains, subways, aircraft, ships, submarines, space craft and other vehicles which can transport humans or cargo. In some instances, the headliner typically comprises at least one core layer and a decorative layer, e.g., a decorative fabric, disposed on the core layer. The decorative layer, in addition to being aesthetically and/or visually pleasing, can also enhance sound absorption and may optionally include foam, insulation or other materials. An illustration of a top view of a headliner is shown in
In certain examples, similar methods can be used to produce underbody shields and automotive trim pieces or parts from the prepreg or core layer including a consolidated, high strength to weight ratio web. An illustration of an underbody shield 1610 is shown in
In certain examples, the core layers and LWRT articles described herein can be used in an automotive vehicle 1810 (
Certain specific examples are described to illustrate further some of the novel and inventive aspects described herein.
A control specimen and a test specimen were prepared to test mechanical properties of thermoplastic composite articles. Each specimen had the following physical properties.
Each specimen included about 2 weight percent micro sphere lofting agent with the balance of the weight being polypropylene so the lofting agent, glass fibers and polypropylene amounts add to 100 weight percent. A protective scrim was present on each side of the tested specimen for protection.
The flexural properties (3-point bending) of the molded specimens in this Example were evaluated using MTS mechanical testing system according to ISO 178 standard (similar to ASTM D790-17). Rectangular specimens (100 mm×30 mm) were cut from plaques in the machine direction (MD) as well as the cross-machine direction (CD). The cross-head speed, span, anvil diameter, and nose diameter were 15 mm/min, 64 mm, 10.0 mm, and 10.0 mm, respectively. The tensile properties of the molded specimens were performed on an MTS mechanical testing machine according to ISO 527 standard. All the specimens were cut into dog-bone shape by a punch press. The span, test speed, and load cell were 115 mm, 5 mm/min, and 5 kN, respectively. For the flexural and tensile test, each dot in the graphs represents the average of 5 replicates, unless stated otherwise. After the mechanical test, the areal density and glass content were re-checked to ensure the consistency and repeatability of the molded specimens.
As shown in
The tensile property was also evaluated with a range of thicknesses (target substrate thickness from 1.0 mm to 4.5 mm). The tensile modulus and tensile slope are shown in
The results are consistent with N-LWRT being capable of achieving around 25% (or 250 g/m2 areal weight) weight reduction without significantly sacrificing the flexural properties compared to the control (S-LWRT). With a higher PP content in N-LWRT and the higher consolidation process, the bonding between the fiberglass and PP resin may be stronger than the S-LWRT material, which can effectively prevent the PP-GF matrix from fiber pull-out or fiber microbuckling.
Additional test specimens including a consolidated, porous core layer were prepared for testing against a control specimen. Each specimen had the following physical properties.
Each specimen included about 2 weight percent micro sphere lofting agent with the balance of the weight being polypropylene so the amount of the glass fibers, lofting agent and polypropylene add to 100 weight percent. A protective scrim was present on each side of the tested specimen for protection.
The 900 gsm SuperLite material was used as a control for the 675 gsm ProLite material, and the 1000 gsm SuperLite material was used as a control for the 750 gsm ProLite material. Each sample was tested by 5 replicates.
The flexural properties (3-point bending) of the molded specimens were evaluated using MTS mechanical testing system according to ASTM D790-17 standard. Rectangular specimens (100 mm×25 mm) were cut from plaques in the machine direction (MD) as well as the cross-machine direction (CD). The cross-head speed, span, anvil diameter, and nose diameter were 15 mm/min, 64 mm, 6.4 mm, and 6.4 mm, respectively. For the flexural test, each dot in the graphs represents the average of 5 replicates, unless stated otherwise. After the mechanical test, the areal density and glass content were re-checked to ensure the consistency and repeatability of the molded specimens.
The flexural properties were evaluated on specimens molded into a variety of thicknesses. As shown in
Similar mechanical properties were observed from comparing 1000 gsm SuperLite material and 750 gsm ProLite material as shown in
When introducing elements of the examples disclosed herein, the articles “a,” “an,” “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including” and “having” are intended to be open-ended and mean that there may be additional elements other than the listed elements. It will be recognized by the person of ordinary skill in the art, given the benefit of this disclosure, that various components of the examples can be interchanged or substituted with various components in other examples.
Although certain aspects, configurations, examples and embodiments have been described above, it will be recognized by the person of ordinary skill in the art, given the benefit of this disclosure, that additions, substitutions, modifications, and alterations of the disclosed illustrative aspects, configurations, examples and embodiments are possible.
This application claims priority to, and the benefit of, U.S. Provisional Application No. 63/352,427 filed on Jun. 15, 2022, the entire disclosure of which is hereby incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 63352427 | Jun 2022 | US |
